Metallurgical industry Atex exploson proof led light application analysis: how to build a high-temperature and high-risk environment safety lighting system?

Atex exploson proof led lights in the metallurgical workshop core role and intelligent get the job done program

First, metallurgical industry lighting what challenges? Why must choose explosion-proof lights?

Metallurgical production environment is known for high temperature, high dust, corrosive gases, explosion risk, traditional lighting equipment is difficult to meet the double demand for safety and efficiency. Atex exploson proof led lights, with their professional design, become the core choice for metallurgical workshop lighting upgrade.

1. Metallurgical workshop four harsh challenges

Explosive gases and dust: coking workshop gas [hydrogen, methane], aluminum electrolysis workshop fluoride dust, metal smelting area zinc / magnesium dust; there is an explosion risk.

Extremely high temperature environment: the temperature around the steelmaking furnace can reach more than 80 ℃, the conventional lights and lanterns are easy to overheating failure or triggering the melting of materials.

Chemical corrosion and mechanical shock: acid mist, alkali mist corrosion circuit, metal splash, equipment vibration led to structural damage to the lights.

Continuous operation and energy efficiency pressure: 24-hour production requires high reliability of lighting, traditional light sources with high energy consumption and frequent maintenance.

2. Atex exploson proof led light core advantages

Explosion-proof safety design: Explosion-proof [Ex d] or dust-proof [Ex tD] structure, approved GB 3836, ATEX certification, effectively isolate the internal arc and the external hazardous environment.

High temperature and corrosion resistance: 316 stainless steel shell + ceramic heat dissipation technology, resistant to extreme temperatures of -40 ℃ ~ +150 ℃, the surface of the fluorocarbon spraying process to resist acid and alkali corrosion.

Energy efficient and long life: LED Atex exploson proof led light luminous efficiency > 140lm / W, life expectancy of more than 60,000 hours, compared with high-pressure sodium lights to save energy by 70%, to reduce the risk of maintenance of high-temperature areas.

Second, Atex exploson proof led lights in the metallurgical industry five core application scenarios and get the program

1 steelmaking furnace and continuous casting area

Demand pain points: high temperature radiation, steel splash, gas leakage.

Solution: choose Ex d IIB T3 Atex exploson proof led light [surface temperature ≤ 200 ℃], power 150W-300W, color temperature 5000K, temperature rating ≥ 150 ℃. Add a metal protective net to prevent steel slag splash damage to the lightshade, lights and lanterns spacing 4-5 meters, illuminance ≥ 200lux.

2. Aluminum electrolysis workshop

Risk characteristics: hydrogen fluoride gas corrosion, high humidity, strong electromagnetic interference.

Technical solutions: Atex exploson proof led light shell material selection Hastelloy C276, protection level IP68, hydrofluoric acid corrosion resistance. It is equipped with electromagnetic shielding layer, which complies with EN 61000-6-2 anti-interference standard, and avoids affecting the control system of electrolyzer.

3. Coking plant and gas purification area

Special requirements: methane/hydrogen gas mixture, hydrogen sulfide corrosion. Recommended configuration: Ex d IIC T4 Atex exploson proof led light [T4 group surface temperature ≤ 135 ° C], with stainless steel explosion-proof junction box, explosion-proof surface gap <0.15 mm.

emergency lighting module with the help of the mains power outage ≥ 120 minutes, to protect the gas leakage emergency treatment lighting.

4. metal powder preparation workshop

Dust explosion-proof requirements: aluminum powder, magnesium powder and other Class IIIA explosive dust environment.

Explosion-proof design: Ex tD A21 IP65 dust explosion-proof certification, the surface temperature of the light < dust cloud ignition temperature 2/3 [such as aluminum powder needs to be < 430 ℃ × 0.67 = 288 ℃].

Anti-static design, surface resistance <1×10⁶Ω, to prevent dust adsorption triggering the accumulation of combustion.

5. Rolling mill and casting area

Mechanical shock protection: heavy equipment vibration, metal parts impact risk. Anti-vibration program: Atex exploson proof led light internal spring shock absorbing bracket, external 304 stainless steel protective cover, anti-vibration performance of more than 20G. Light source module and drive power supply sub-cavity design, reduce the vibration caused by circuit failure rate.

Thrid, metallurgical industry Atex exploson proof led light selection four core indicators

1. Accurate matching of explosion-proof grade

Gas / dust classification: gas explosion-proof: Class IIC [hydrogen], Class IIB [ethylene], Class IIA [propane]. Dust explosion-proof: IIIA [metal dust], IIIB [coal dust], IIIC [fiber dust]. Temperature group: T1 [≤ 450 ℃] to T6 [≤ 85 ℃], steelmaking furnace periphery needs to be at least T3 group [≤ 200 ℃].

2. High temperature resistance and heat dissipation design

Heat dissipation technology: ceramic substrate + heat pipe cooling structure to ensure that the LED junction temperature <85 ℃, light decay rate <5% / 10,000 hours. Material selection: 310S stainless steel for high-temperature area [1100℃], die-cast aluminum for regular area [150℃].

3. Protection and corrosion resistance

Protection level: IP66 [dustproof and waterproof] or IP68 [water immersion environment], acid fog area needs additional approval ISO 9227 salt spray test ≥ 1000 hours. Surface treatment: electrostatic spraying [thickness ≥ 80μm] or PTFE coating, resistant to pH 2-12 chemical corrosion.

4. Intelligent control and energy efficiency management

Dimming strategy: automatically switch 100%/50% brightness according to production shifts, energy saving over 40%. IOT integration: Approved 4G/5G module to monitor the status of lights and lanterns in real time, abnormal data is pushed to the central control system.

Fourth, Atex exploson proof led light installation and maintenance of the whole process specification

1. Specialized installation points

Seal processing: cable inlet using double rubber seals + explosion-proof glands [specifications M20×1.5], explosion-proof surface coated with 650 ℃ high-temperature grease. Layout improvement: High temperature area lights and lanterns are ≥1.5 meters away from the heat source to avoid heat radiation accelerated aging.

2. Periodic maintenance strategy

Monthly inspection: Clean the radiator dust, check whether the protective net is deformed, and replace the lightshade if the light transmittance decreases by more than 20%. Annual inspection: use explosion-proof parameter tester to verify the explosion-proof gap, insulation resistance >5MΩ [hot and humid environment needs to be >2MΩ].

3. Intelligent operation and maintenance system

Digital twin platform: 3D modeling of workshop lighting system, AI prediction of light life, accurate management of spare parts inventory, AR remote assistance: maintenance personnel approve AR glasses to obtain real-time maintenance guidelines to reduce downtime.

Fifth. Future Momentum: Green and Intelligent Technology Reshaping Metallurgical Lighting

DC micro-grid power supply: photovoltaic + energy storage system with DC24V Atex exploson proof led lights, reducing cable losses and improving the reliability of emergency power supply.

UV-C disinfection integration: Atex exploson proof led lights with built-in 275nm UV module, synchronized lighting and air sterilization in the foundry.

Digital twin and AI operation and maintenance: Approve machine learning to analyze the operation data of lights and lanterns, and dynamically improve the lighting energy consumption and maintenance cycle.

Conclusion

Metallurgical industry safety production is inseparable from the high reliability of the lighting system, Atex exploson proof led lights approved explosion-proof, high temperature resistance, corrosion resistance and other characteristics, into a high-temperature and high-risk environment lighting guardian.

As a professional service provider in the field of industrial lighting, Amasly Lighting supplies Atex exploson proof led lights for metallurgical industry to handle the whole scenario, from explosion-proof certification, customized heat dissipation design to intelligent operation and maintenance management, to help enterprises to implement safe, efficient and sustainable production intentions.

Get Metallurgical Workshop Explosion-proof Lighting Program → Amasly Lighting

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